Traction battery spacer with retention element

ABSTRACT

A battery assembly includes a plurality of cells stacked to form an array and a plurality of spacers each disposed between an adjacent pair of the cells. Each cell includes at least one terminal. Each of the spacers includes a retainer extending from an edge portion of the spacer. The retainers are configured to orient and engage a busbar for connecting the terminals of an adjacent pair of cells. The battery assembly may also include a busbar module. The busbar module may engage with the retainers to hold the busbar module to the array.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a division of U.S. application Ser. No. 14/173,448filed Feb. 5, 2014, now U.S. Pat. No. 9,972,815, issued May 15, 2018,the disclosure of which is hereby incorporated in its entirety byreference herein.

TECHNICAL FIELD

This disclosure relates to battery cell spacers for vehicle batteryassemblies.

BACKGROUND

Vehicles such as battery-electric vehicles (BEVs), plug-in hybridelectric vehicles (PHEVs) or hybrid-electric vehicles (HEVs) contain abattery assembly with a traction battery to act as an energy source forthe vehicle. The battery assembly may include components and systems tointeract with the battery and assist in managing vehicle performance andoperations. The battery may include one or more arrays of battery cellswith the cell terminals interconnected electrically with busbars.

SUMMARY

A battery assembly includes a plurality of cells stacked to form anarray. Each cell includes a terminal. The assembly also included aplurality of spacers each disposed between an adjacent pair of the cellsand each including a retainer extending from an edge portion of thespacer. Each of the retainers is configured to orient and engage abusbar connecting the terminals of an adjacent pair of the cells.

A battery assembly includes a plurality of cells stacked to form anarray. Each cell includes a terminal. The assembly also includes aplurality of spacers each disposed between an adjacent pair of the cellsand including a retainer extending from an edge portion of the spacer,and at least one busbar module. The busbar module includes a housingconfigured to protect and align a plurality of busbars, and a flapattached to the housing. The flap is configured to engage acorresponding retainer to secure the flap against a corresponding cell.

A battery assembly includes a plurality of cells stacked to form anarray having first and second terminal rows, and a plurality of spacerseach disposed between an adjacent pair of the cells and including a clipextending from an edge portion of the spacer. The assembly also includesa busbar module including first and second side portions interconnectedby a middle portion. Each of the side portions is disposed over one ofthe first and second terminal rows and includes at least one busbarelectrically connecting two adjacent terminals in the correspondingterminal row. The middle portion defines a plurality of slots. Each ofthe slots receives a corresponding clip therethrough to secure thebusbar module to the array.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a battery assembly.

FIG. 2 is a side view of the battery assembly shown in FIG. 1 with adifferent retainer.

FIG. 3 is a perspective view of the battery assembly shown in FIG. 1with another different retainer.

FIG. 4 is a perspective view of a battery assembly including a busbarmodule.

FIG. 5A is a perspective view of another battery assembly including abusbar module.

FIG. 5B is a top view of the battery assembly shown in FIG. 5A.

FIG. 5C is a section view of the battery assembly shown in FIGS. 5A and5B along cut 5C-5C.

DETAILED DESCRIPTION

Embodiments of the present disclosure are described herein. It is to beunderstood, however, that the disclosed embodiments are merely examplesand other embodiments can take various and alternative forms. Thefigures are not necessarily to scale; some features could be exaggeratedor minimized to show details of particular components. Therefore,specific structural and functional details disclosed herein are not tobe interpreted as limiting, but merely as a representative basis forteaching one skilled in the art to variously employ the presentinvention. As those of ordinary skill in the art will understand,various features illustrated and described with reference to any one ofthe figures can be combined with features illustrated in one or moreother figures to produce embodiments that are not explicitly illustratedor described. The combinations of features illustrated providerepresentative embodiments for typical applications. Variouscombinations and modifications of the features consistent with theteachings of this disclosure, however, could be desired for particularapplications or implementations.

Referring to FIG. 1, a battery assembly 10 is shown. The batteryassembly 10 includes a plurality of battery cells 12 stacked to form abattery array 14. Each of the battery cells 12 includes positive andnegative terminals 16. A plurality of spacers 18 are provided betweenadjacent pairs of the cells 12. The spacers may provide electricalisolation and/or cooling between adjacent cells. Each spacer 18 includesa retainer 20. The retainer 20 may be connected to the edge portion 22at a corner 26 of the spacer 18. The spacers 18 may be arranged suchthat the retainers 20 on adjacent spacers 18 are on opposing corners oftheir corresponding spacer 18 such that the retainers 20 alternate alongthe array 14. For example, a first spacer has the retainer 20 attachedon a left corner of the spacer and an adjacent spacer has the retainer20 on the right corner.

The retainers 20 are for securing a plurality of busbars 28 to thebattery array 14. Including the busbar retention device (i.e. retainer20) on the spacer may reduce the need for other busbar attachmentcomponents. This may reduce production costs and increase manufacturingefficiencies. Each busbar 28 electrically connects adjacent positive andnegative terminals 16. Each of the retainers 20 engages with at leastone busbar 28 to secure the at least one busbar 28 to the terminals 16.Each retainer 20 may include a first clip 30 and a second clip 32. Thefirst and second clips 30, 32 are disposed on opposing sides of theretainer 20 with the first clip 30 being nearer to the corner then thesecond clip 32. The first and second clips 30, 32 engage with opposinglongitudinal sides 34 of the busbar 28 and cooperate to secure one endof the busbar 28 to the corresponding terminals. A retainer 20 locatedin the interior of the battery array 14 may additionally include a thirdclip 33 and a fourth clip 35. The third and fourth clips 33, 35 areidentical to the first and second clips 30, 32. The third and fourthclips 33, 35 engage with opposing longitudinal sides 34 of anotherbusbar 28 and cooperate to secure one end of that busbar to thecorresponding terminals. A separator 37 is disposed between the two setsof clips to prevent adjacent busbars 28 from short circuiting. Each clip30, 32, 33, 35 includes a body portion 36 that is attached to the edgeportion 22 of the spacer 18 and projection 38 that extends away from thebody portion 36. The projection 38 is configured to engage with a topside 40 of the busbar 28 when the busbar 28 is installed on the batteryarray 14.

FIG. 2 illustrates an alternative retainer design for the batteryassembly 10. Each retainer 50 includes a body portion 52 and a headportion 54. The body portion 52 connects to the spacer 18 at the edgeportion 22. The head portion 54 is disposed on the body portion 52opposite the edge portion 22. The head portion 54 includes at least oneprojection 56. The projection 56 and the body portion 52 cooperate todefine a slot 58. The slot 58 receives a portion of the busbar 28 tosecure one end of the busbar 28 to the array 14. A flap 60 may beattached to the head portion 54 via a living hinge 62. The flaps 60provide finger protection for the busbars 28. The flaps 60 are pivotablebetween open and closed positions. Each retainer 50 also includes a snap66. The snap 66 is disposed on the head portion 54. A distal end 64 ofthe flap 60 engages with the snap 66 of an adjacent retainer 50 when theflap 60 is in the closed position.

FIG. 3 illustrates a battery assembly 10 having another alternativeretainer design. As previously described the battery assembly 10includes a plurality of battery cells 12 stacked to form an array 14 anda plurality of spacers 18 disposed between the cells 12. Each spacer 18includes a retainer 70 attached at the edge portion 22. Each retainer 70includes a flap 72. The flap 72 is pivotable about a hinge 74. The hinge74 may be a living hinge. The flap 72 includes a bottom surface 76. Thebottom surface 76 has a plurality of clips 78. The clips 78 areconfigured to receive and secure a corresponding busbar 28 to the bottomsurface 76 of the flap 72. The busbar is an electrically conductivematerial, such as a piece of cooper and/or aluminum. The busbar may bein any suitable shape such a rectangle or a “U”-shape. FIG. 3illustrates one rectangular busbar and four “U”-shaped busbars, howeverit is to be understood that any combination of different shaped busbarsmay be used. Alternatively, all of the busbars 28 may be the same shape.The flap 72 is movable between an open position and a closed position.In the open position, the busbar 28 is not in contact with correspondingterminals 16 and in the closed position, the busbar 28 is in contactwith the terminals 16. The flaps 72 provide finger protection over thebusbar 28 to limit unwanted contact with the busbars 28. Each retainer70 also includes a snap 80. The snap 80 is disposed on the retainer 70proximate the hinge 74. A distal end 82 of the flap 72 engages with thesnap 80 of an adjacent retainer 70 when the flap 72 is in the closedposition. The adjacent retainer may be connected to a spacer 18 that islocated two spacers away. Apertures 84 may be provided through each flap72 to allow welding of the busbars 28 to the terminals 16.

Referring to FIG. 4, a battery assembly 81 is shown. The batteryassembly 81 includes a plurality of battery cells 83 stacked to form abattery array 85. Each of the battery cells 83 includes positive andnegative terminals 86. A plurality of spacers 88 are provided betweenadjacent pairs of cells 83. Each spacer 88 includes a pair of retainers90 located on opposite sides of a centerline of the battery array 85.Each retainer 90 is connected to the edge portion 92 of the spacer 88.Each retainer 90 includes a body portion 104 that is attached to thespacer 88 and at least one finger portion 106 that extends outwardlyfrom the body portion 104. Retainers 90 on interior spacers 88 mayinclude two finger portions 106 that extend in opposite directions. Thefinger portion(s) 106 may be oriented to extend away from the bodyportion 104 transverse to the longitudinal axis of the edge portion.

A pair of busbar modules 94 is attached to the battery array 85. Eachbusbar module 94 is disposed over a corresponding row of terminals. Eachbusbar module 94 includes a housing 96 for protecting and aligning aplurality of busbars 98. Each busbar module 94 also includes a pluralityof flaps 100 that are pivotable about a living hinge 102 on the housing96. The flaps 100 snap into the finger portions 106 of the retainers 90to secure the flaps 100 against the cells 83. The flaps 100 andretainers 90 may also secure and align the busbar modules 94 to thearray 85. Each flap 100 includes a first surface 108 and a secondsurface 109. The first surface 108 is configured to engage with thefinger portions 106 of two adjacent spacers 88. The second surface 109is configured to be disposed against a top side 115 of a correspondingcell 83. A temperature sensor 111 may be provided in the flap 100. Atemperature sensor 111 may be provided in all of the flaps 100 or mayonly be provided in select flaps. A sensor head 113 of the temperaturesensor 111 is disposed on the second surface 109 and is in contact withthe top side 115 of the cell 83. The temperature sensor 111 may be athermistor. Cell temperature sensors function more accurately when heldin contact with a portion of the cell. By providing the temperaturesensor in the flap 100 and securing the flap 100 against the cell 83with the retainer 90, additional locating components, such a springfeature on the temperature sensor may be omitted. This may reducetemperature sensor costs and increase production efficiencies.

Referring to FIGS. 5A to 5C, a battery assembly 110 is shown. Thebattery assembly 110 includes a plurality of battery cells 112 stackedto form a battery array 114. Each of the battery cells 112 includespositive and negative terminals 116. The positive and negative terminals116 define a first terminal row 118 and a second terminal row 120. Aplurality of spacers 122 are provided between adjacent pairs of cells112. Each spacer 122 includes a clip 124 attached to the spacer 122 atan edge portion 126. The clip 124 may be attached to the edge portion126 at a center point of the spacer 122. Each clip 124 includes a headportion 128 and a neck portion 130. The neck portion 130 is attached tothe spacer 122. The head portion 128 is attached to the neck portion 130opposite the edge portion 126. The head portion 128 may be taperedhaving an arrow head cross-section and include a projection 132 thatextends away from the neck portion 130. The head portion 128 and neckportion 130 cooperate to define a notch 134.

A busbar module 136 is attached to the battery array 114. The busbarmodule 136 includes a first side portion 138 and a second side portion140. The first and second side portions 138, 140 are interconnected by amiddle portion 142. The first side portion 138 is disposed over thefirst terminal row 118. The second side portion 140 is disposed over thesecond terminal row 120. A plurality of busbars 144 is disposed withinthe first and second side portions 138, 140 of the busbar module 136.The busbars 144 electrically connect two adjacent terminals 116. Themiddle portion 142 defines a plurality of slots 146. The slots 146receive the clips 124 therethrough to secure the busbar module 136 tothe battery array 114. The head portion 128 is tapered to allow thebusbar module 136 to be pushed onto the clip 124. Once pushed on, thenotch 134 engages with the busbar module 136 to secure the busbar module136 to the array 114. The location of the clips 124 and the slots 146are predefined and help align the busbar module 136 on the battery array114. The busbar module 136 may include a plurality of apertures in thefirst and second side portions 138, 140 to allow access to weld thebusbars 144 to corresponding terminals 116.

While exemplary embodiments are described above, it is not intended thatthese embodiments describe all possible forms encompassed by the claims.The words used in the specification are words of description rather thanlimitation, and it is understood that various changes can be madewithout departing from the spirit and scope of the disclosure. Aspreviously described, the features of various embodiments can becombined to form further embodiments of the invention that may not beexplicitly described or illustrated. While various embodiments couldhave been described as providing advantages or being preferred overother embodiments or prior art implementations with respect to one ormore desired characteristics, those of ordinary skill in the artrecognize that one or more features or characteristics can becompromised to achieve desired overall system attributes, which dependon the specific application and implementation. These attributes caninclude, but are not limited to cost, strength, durability, life cyclecost, marketability, appearance, packaging, size, serviceability,weight, manufacturability, ease of assembly, etc. As such, embodimentsdescribed as less desirable than other embodiments or prior artimplementations with respect to one or more characteristics are notoutside the scope of the disclosure and can be desirable for particularapplications.

What is claimed is:
 1. A battery assembly comprising: a plurality ofcells stacked to form an array having first and second terminal rows; aplurality of spacers each disposed between an adjacent pair of the cellsand including a clip extending from an edge portion of the spacer; and abusbar module including first and second side portions interconnected bya middle portion, wherein each of the side portions is disposed over oneof the first and second terminal rows and includes at least one busbarelectrically connecting two adjacent terminals in the correspondingterminal row, wherein the middle portion defines a plurality of slots,and wherein each of the slots receives a corresponding clip therethroughto secure the busbar module to the array.
 2. The battery assembly ofclaim 1 wherein each of the clips is located at a center point on acorresponding one of the edge portions and each slot is located along acenterline of the middle portion.
 3. The battery assembly of claim 1wherein each of the clips further includes a head portion connected tothe edge portion by a neck portion and wherein the head and neckportions cooperate to engage the busbar module.
 4. The battery assemblyof claim 3 wherein the slots are rectangular.
 5. The battery assembly ofclaim 3 wherein the head portion is tapered to have an arrow headcross-section and has a projection that extends away from the neckportion.
 6. The battery assembly of claim 4 wherein the head portion andneck portion cooperate to define a notch.
 7. The battery assembly ofclaim 1 wherein the busbars are U-shaped.
 8. The battery assembly ofclaim 1 wherein the cells are prismatic cells.
 9. The battery assemblyof claim 8 wherein the cells include tops and the terminals are disposedon the tops.
 10. The battery assembly of claim 1 wherein the cells areprismatic cells.
 11. A battery assembly comprising: a plurality of cellsstacked to form an array having first and second terminal rows; at leastone spacer disposed between an adjacent pair of the cells and includinga clip extending from an edge portion of the spacer; and a busbar moduleincluding first and second side portions interconnected by a middleportion, wherein each of the side portions is disposed over one of thefirst and second terminal rows and includes at least one busbarelectrically connecting two adjacent terminals in a corresponding one ofthe terminal rows, wherein the middle portion defines at least one slotthat receives the clip therethrough to secure the busbar module to thearray.
 12. The battery assembly of claim 11 further comprising a secondspacer between another adjacent pair of the cells and including a secondclip extending from an edge portion of the spacer, wherein the middleportion defines a second slot that receives the second cliptherethrough.
 13. The battery assembly of claim 11 wherein the clip islocated at a center point on the edge portion and the slot is located ona centerline of the middle portion.
 14. The battery assembly of claim 11wherein the clip further includes a head portion connected to the edgeportion by a neck portion.
 15. The battery assembly of claim 14 whereinthe head portion is tapered to have an arrow head cross-section and hasa projection that extends away from the neck portion.
 16. The batteryassembly of claim 15 wherein the head portion and neck portion cooperateto define a notch.
 17. A battery assembly comprising: a plurality ofcells each having terminals, the cells being arranged in an array withthe terminals aligned to form first and second terminal rows; at leastone spacer disposed between an adjacent pair of the cells and includinga clip extending from the spacer; and a busbar module including firstand second side portions having busbars and a middle portion defining aslot, wherein the busbar module is seated on the array with the busbarselectrically connecting between corresponding ones of the terminals andwith the clip extending through the slot to secure the busbar module tothe array.
 18. The battery assembly of claim 17 further comprising asecond spacer between another adjacent pair of the cells and including asecond clip extending from the spacer, wherein the middle portiondefines a second slot that receives the second clip therethrough. 19.The battery assembly of claim 17 wherein the at least one spacer is aplurality of spacers and each adjacent pair of the cells has acorresponding one of the spacers sandwiched therebetween, and whereinthe slots is a plurality slots that each receive one of the clips. 20.The battery assembly of claim 17 wherein the spacer includes an edgeportion, and the clips extends from the edge portion.